Detect Equipment Wear Sooner with Ferrous Debris Analysis

In the world of heavy-duty equipment, small issues can quickly become big problems. A worn bearing or damaged gear doesn’t just cause mechanical headaches , it can lead to costly downtime, safety risks, and unexpected repairs. That’s why early detection of wear is one of the most valuable tools in any maintenance strategy.

One of the most effective ways to spot wear early is through ferrous debris analysis. This is a key part of fluid testing that helps you understand what’s happening inside your equipment long before performance declines.

What is Ferrous Debris?

Ferrous debris refers to the tiny metal particles (typically iron and steel) that are generated when internal components begin to wear. These particles are carried in the lubricant and can tell a detailed story about what’s happening inside an engine, gearbox, or hydraulic system.

While some wear is normal, a sharp increase in ferrous debris is often one of the first signs that something is going wrong. Identifying these particles early helps maintenance teams take corrective action before the wear turns into failure.

Why Testing Matters

Routine oil analysis provides an overview of fluid health and contamination, but ferrous debris testing focuses specifically on wear; the earliest and most direct indicator of mechanical distress. By trending ferrous data over time, maintenance professionals can spot abnormal wear patterns and schedule repairs before they become emergencies.

The Next Generation of Wear Detection: FerroQ

Traditionally, laboratories have used Particle Quantifier (PQ) testing to measure the amount of ferrous material in a lubricant sample. While effective, PQ testing can have limitations when dealing with complex samples or heavy contamination.

That’s why POLARIS Laboratories® has implemented the FerroQ method across all laboratory locations. FerroQ is an advanced approach to ferrous debris analysis that delivers more accurate, consistent, and repeatable results — giving you a clearer picture of equipment condition. Learn more about the switch here.

With FerroQ, you get:

  • Improved precision for detecting even small changes in wear levels

  • Faster, more reliable trending for better long-term insight

  • Consistent results across all POLARIS Laboratories® locations

This consistency ensures that wherever you send your samples, you’ll receive the same high-quality data, making it easier to monitor trends and take action with confidence.

Turning Insight into Action

Ferrous debris analysis doesn’t just measure metal content — it helps identify the type of wear occurring. When combined with techniques like Analytical Ferrography, maintenance teams can determine whether particles are from normal rubbing, cutting wear, or fatigue failure.

This level of insight allows you to move from reactive maintenance to a truly proactive, data-driven approach — extending equipment life, improving reliability, and maximizing return on investment.

The Bottom Line

When every hour of uptime matters, early detection makes all the difference. With advanced ferrous debris testing like FerroQ, you can identify wear before it becomes damage — keeping your equipment running stronger, longer.

Published October 24, 2025

Get More from Your Lubricants: How Oil Analysis Can Optimize Drain Intervals

In today’s market, lubricant supply challenges are pushing maintenance teams to rethink how they manage oil drain intervals. From additive shortages and rising demand to logistical delays, getting the lubricant you need when you need it isn’t as easy as it used to be.

How can you get the most of the lubricants?

The answer lies in oil analysis.

Routine oil analysis is a powerful tool for extending and optimizing drain intervals without risking equipment reliability. Instead of relying solely on preventive maintenance (PM) schedules or disposing of used oil without checking its remaining life, consider switching to a condition-based monitoring (CBM) strategy. With CBM, sample results guide your maintenance actions, allowing you to safely push drain intervals further while monitoring for wear, contamination and fluid health.

Lubricants can often be safely used beyond OEM-recommended intervals, but only when supported by testing and analysis. A routine fluid analysis program evaluates the oil’s physical properties, identifies signs of wear and determines if the fluid can still perform effectively. POLARIS Laboratories® offers customers an Extended Drain Comments Program where our team of support analysts help you determine how to reach optimal lubricant usage.

At a time when it’s needed the most, oil analysis can reduce costs, minimize waste and lower maintenance spend.

For more insight into optimizing drain intervals and getting more from your lubricants, check out this infographic:

Contact your Account Manager or Customer Experience (service@eoilreports.com) to learn more about participating in the Extended Drains Program at POLARIS Laboratories®.

Coming Soon: Ferrous Debris Analysis with FerroQ

Out with PQ, in with FerroQ.

Starting September 11, 2025, POLARIS Laboratories® will transition all of our laboratory facilities from the PQ™ (Particle Quantifier) test method to the more advanced FerroQ™ instrument for ferrous debris analysis. This upgrade applies to both oil and grease sample testing and marks a significant improvement in how wear-related ferrous debris is measured, interpreted and reported.

To learn more about different types of wear, ferrous debris and tests performed to measure it, watch the webinar Ferrous Debris 101: What Your Lubricant is Telling You:

Enhanced Ferrous Debris Analysis with FerroQ

Instead of results reported in PQ Index (a unitless number), results will be reported in parts per million (ppm) on analysis reports delivered to customers. This change delivers greater accuracy, improved trendability and more reliable data for identifying wear and making informed maintenance decisions.

Why the change?

The FerroQ™ method provides a clearer, more quantifiable picture of ferrous contamination, making it easier to detect early-stage wear and better predict component failure. It also enhances consistency across sample reports and allows for easier integration with maintenance data systems.

For more technical information related to ferrous debris, testing limitations and particle debris measurement, read the blog Assessing Methods to Analyze Particles: PQ vs FerroQ or view the Technical Bulletin PQ vs FerroQ.

As your fluid analysis laboratory and reliability partner, our goal is to help you make smarter data-driven decisions based on the most reliable results and the FerroQ™ is the next step forward. Customers can expect to receive additional communication when the change goes into effect in the coming months.

If you have any questions, please contact service@eoilreports.com.

2025 Reliability Summit

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Catch Pesky Particle Contamination

Did you know 80% of failures in hydraulic systems can be traced back to contamination? Particle contamination is the most common, most detrimental type of contamination, can come from many different sources and can include dirt, metal, soot and rust.

How do these pesky particles enter your system?

Sources contributing to particle contamination can include:

  • Lubricant additives
  • Sample bottle cleanliness
  • Poor oil sampling procedures
  • Air entrainment
  • Use of improper reservoir covers
  • Transport, distribution and transferring of new lubricants

Due to the wide range of potential sources and cause of particle contamination, it’s important to identify it before it can cause issues including:

  • Increased wear and tear on bearings, gears and seals
  • Lubricant degradation
  • Clogged filters causing fluid flow restriction
  • Pitting, scoring or cracking in critical components
  • System malfunction (jammed valves and surface erosion)
  • Overheating

Performing Particle Count Testing 

If you have pesky particle contaminates within your system, chances are standard testing with Inductively Coupled Plasma (ICP) won’t catch the real problem. ICP can only fully analyze a particle at approximately 10 µm in diameter and gives no indication of the morphology or distribution of the particles.

Particle count is one of the best available tools for measuring system cleanliness. This test is suitable for most (but not all) fluid types and systems and can count particles as small as ≥ 4 µm and can lead maintenance professionals to identify the source of the contamination and assess the damage that has occurred to the component.

Evaluating the use case, objectives, and system type are key to determining whether particle count and other tests may provide the most valuable data. Particle count is crucial to maintaining the performance and longevity of sensitive components with small clearances.

It is recommended to perform particle count testing to determine the number and size of particles in these components:

  • Hydraulics
  • Compressors
  • Turbines
  • Circulating systems
  • Automatic transmissions
  • Natural gas engines
  • Robotics
  • Injection molding machines
  • Bearing and gear systems

Should you be performing Particle Count to address system contamination? View the HORIZON Technical Bulletin Particle Count: When to Use it and Why

Explore different test methods for counting particles in the HORIZON Technical Bulletin Particle Count Test Techniques

Ready to improve system cleanliness and address those pesky particles?

Contact your Account Manager or Customer Experience at service@eoilreports.com or call +1 317-808-3750.

Published January 7, 2025

Diesel Exhaust Fluid (DEF) Testing is Now Available

POLARIS Laboratories® is excited to offer our customers testing and analysis for Diesel Exhaust Fluid (DEF).

DEF, also known as AUS 32 and marketed as AdBlue, is a water and urea mixture that is non-toxic, colorless and non-flammable. The aqueous urea solution is comprised of 32.5% urea and 67.5% deionized water.

Testing for DEF will include:

  • Elemental analysis
  • Visual examination
  • % Urea
  • pH
  • Specific Conductance

Because DEF manufacturers perform specification testing following the ISO 22241 guidelines, POLARIS Laboratories® will not provide this testing.

Testing your DEF can identify concerns of contamination that can result in a decrease in engine performance capabilities. The above tests will provide a comprehensive check for contamination within the DEF in-service fluid. Including comprehensive testing will provide awareness and indicate actions required to maintain the engines’ proper performance.

As DEF is consumed by the engine, the fluid in the tank on the equipment will eventually be depleted and new fluid will be added. Addressing identified contamination concerns early will avoid potential future issues in the system.

Reach out to our team today to add DEF testing to your fluid analysis program.

Go Digital with Your Condition Monitoring

As the industry continues to grow in the digital landscape, POLARIS Laboratories® is always looking for ways to maximize customers’ access to technology. With tools such as Component ID Tags, QR-Code-Only Sample Labels and the HORIZON® mobile app, our customers can digitally customize how they manage their fluid analysis programs.

QR-Code Only Sample Labels

QR-Code Only Sample Labels contain a unique barcode number linked to a specific fluid sample, made to easily apply to the surface of the sample bottle. By transitioning to QR-Code Only Sample Labels, customers can reduce the costs of kits while simultaneously improving the overall carbon footprint.

Start using QR-Code Only Samples and:

  • Eliminate handwritten submissions
  • Minimize paper waste
  • Accelerate result time
  • Manage previous submission information
  • Save on costs of kits

Read more on QR-Code Only Sample Labels

Streamline Submissions Through Component ID Tags

Registering equipment information has been made easier using Component ID Tags. Implementing the use of these QR tags minimizes time spent registering samples in HORIZON and ensures data accuracy.

Use Component ID QR Tags on equipment and:

  • Eliminate manually entered ID’s
  • Maintain component ID integrity
  • Decrease registration steps
  • Increase productivity

Get Connected Anywhere Through the HORIZON Mobile App

Implementing the use of QR codes works in tandem with the HORIZON mobile app. Customers can avoid paperwork and access fluid analysis data in HORIZON anywhere, anytime. The HORIZON mobile app gives customers unlimited access to view their equipment list, sample data history, view reports and more all within the reach of their pocket.

The mobile app allows customers to:

  • Register samples
  • Scan QR codes
  • Receive and view reports
  • Add and duplicate equipment
  • Set up custom alerts based on report severity

The mobile app allows customers to edit fields including:

  • Component ID
  • Fluid type
  • Component type
  • Manufacturer
  • Model
  • Filter type
  • Application

Stay Alert Anywhere You Go

Keeping up with the digital age and taking your fluid analysis program digital means quicker sample registration and faster response time to critical issues before they turn catastrophic.

POLARIS Laboratories® prioritizes our customers’ reliability through providing services that increase program efficiency. As we continue to innovate using technology to streamline our programs, we hope customers utilize these tools to effectively monitor their equipment.

Introducing Our New Mascot: Beecon, the ReliaBee

Introducing Our New Mascot: Beecon, the ReliaBee

In celebration of POLARIS Laboratories’ 25th Anniversary and the significant advancements driven by our dedicated team members and valued customers; we are proud to unveil our new mascot. Meet Beecon, the Reliabee!

Putting the B in Reliability

Beecon represents our steadfast commitment to excellence, collaboration and dedication in assisting our customers achieve peak equipment reliability through fluid analysis. At POLARIS Laboratories®, we strive to provide accurate, reliable and timely results, personalized customer experience, expert recommendations and collaborative insights.

A Beecon Towards Value

Much like our guiding POLARIS star, the name Beecon symbolizes both aiding navigation and orienting position or location. From the very beginning, POLARIS Laboratories has prioritized delivering state-of-the-art navigational data management and integration technology solutions aimed at ensuring our users achieve total equipment reliability. Through HORIZON®, our customers gain access to a robust suite of information and tools that help them take their maintenance program management capabilities to the next level.

Sample Data as Sweet as Honey

Actionable maintenance recommendations, expert analysis and accuracy of test results are integral to the operational efficiency at POLARIS Laboratories®, reflecting the meticulous processes observed within a beehive. Much like bees maintain hive health through careful oversight and teamwork, our customers rely on us to help them improve operational efficiency, predict maintenance and optimize fluid drain intervals safely. POLARIS Laboratories® is the “Beecon” on our customers’ reliability journey, guiding them with precision and clarity.

Welcome, Beecon the ReliaBee

At POLARIS Laboratories®, we value the dedication of our teams, ensuring smooth and efficient operations. Our commitment to engaging customers in effective maintenance strategies reflects our core values. Beecon exemplifies the reliability, performance and excellence that define POLARIS Laboratories®.

Published July 9, 2024

Staying Cool for the Summer: How to Utilize Coolants During Hot Temps

With the summer months coming, assessing your cooling system is more important than ever to prevent equipment overheating.

As the outside temperatures rise during the summer months, equipment concerns come into focus. Engine metallurgy and lubrication relies on a specific temperature range while in-service. Anything outside of this range will result in reduced efficiency and prolonged exposure to high internal temperatures will increase component wear and lubricant stress. The viscosity of the lubricant is crucial for providing a fluid film to avoid metal to metal contact. Overheating will cause the lubricant’s viscosity to become too thin for proper protection. This affects lubrication, resulting in friction, wear and shortening the lubricant’s capabilities to provide proper protection to the system.

The Functions of a Cooling System

The cooling system becomes a driving reminder to the importance of regulating the engine temperature. The cooling system must be able to circulate coolant, remove heat from the system and dissipate the heat. To keep overall internal temperatures stable during outside temperature shifts, the cooling system must function correctly. However, if one of the functions cannot perform properly, this will cause a snowball effect of concerns.

The effects of temperature, pressure, flow on the cooling system operation, will noticeably impact equipment health. Corrosion in the cooling system occurs at a slower rate than engine wear; however, up to 40% of preventable engine failures are traced back to the cooling system. Concerns with the lubricant and engine performance may be a sign of cooling system issues.

Click here to read more on the effects on the cooling system

The Importance of Coolants

Coolant in the cooling system plays a critical role in the ability to transfer heat and prevent corrosion protecting the overall system health. Overheating is a common concern due to coolant property issues. Increased summer heat might also increase unexpected failures. The frequently acknowledged coolant properties that are reduce corrosion in the cooling system and lubricant concerns are:

• Glycol Concentration
• pH
• Corrosion Protection Inhibitors
• Concerns of Contamination
• Degradation Acids

Maintaining Coolant Systems for Improved Longevity

Coolant chemistry reactions occur due to mechanical issues, coolant property concerns or contamination of the system. Warmer temperatures should not keep your equipment out of service or increase lubrication costs. Maintaining your cooling system can be a simple task to avoid resulting in a neglected system. Understanding coolant and equipment demands is key to proper maintenance in the field. With consistent maintenance, the coolant and equipment health can provide adequate functions to protect and remove heat from the component parts as needed.

A proper fluid analysis program should include assessing all fluids in the equipment. Your fluid analysis program will remove maintenance guesswork for whether the equipment components are appropriately supported and protected or not. With trend analysis, you can reliably catch concerns and are able to act on the recommendations and address the issue before further damaging your equipment. Reach out to our team today to see how we can help see your fluid analysis program succeed and achieve your ROI.

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Published June 25, 2024

25 Years Strong of Proven Impact, Uptime & Savings

Since opening our doors in 1999, POLARIS Laboratories® has had a mission to provide reliable data, analysis and information to our customers so they can save more equipment.We started off with big ambitions with Jeff White, Mark Minges, Don Woods, Robin Batt, Kevin Batt leading the charge and Bryan Debshaw joining with his aligning entrepreneurship vision soon after. From there, the company has evolved into the POLARIS Laboratories® we all know today. From every corner of the company, we pride ourselves in providing our customers with reliable information and maintenance recommendations and will continue to provide the same quality results for the next 25 years and beyond. While looking back at our last quarter century of achievements, we want to commemorate the vast amount of progress we’ve made as a team since the very beginning.

The journey of POLARIS Laboratories® has been remarkable. In celebration of our 25 years working with brilliant minds and dedicated customers, we would like to take you all on a tour of our history and accomplishments throughout the years.

The POLARIS Laboratories’ Impact on Savings 

POLARIS Laboratories® has been hard at work ensuring our customers get the best results when they need them the most. Through 25 years of testing, analyzing and providing insights into equipment-saving actions, we’ve produced:

  • 68,000+ pieces of equipment saved from failure
  • 2,800,000+ critical severity reports delivered
  • $300,000,000+ customer maintenance dollars saved

It is hard to believe the amount of hard work and dedication those in our labs and other sectors of POLARIS Laboratories® have contributed to build the reputation we have now. The impact we have made by continuing to push limits and set new goals for ourselves has driven our company since its very foundation.

The Gallery of POLARIS Laboratories® Major Projects

From 1999 to 2024, the number of projects and accomplishments has only grown and expanded. Some value-add services we’ve built up in the years we’ve grown include:

Increasing fluid testing, lab openings, available platforms and more has given our customers more options than ever. We started with oil and continuously expanded our expertise into coolants, fuel and grease. Eventually we’d extend into specialties such as Filter Debris Analysis (FDA), Micopatch, and Analytical Ferrography (AF). Our understanding of the usefulness of tools and applications has allowed us to continuously expand our offerings to meet our customers’ needs.

The POLARIS Laboratories’ Global Expansion Timeline

Through the goal of building up our laboratories, we aimed to bring our services to as many customers as possible as we’ve expanded globally. The timeline of our growing laboratory locations include:

Indianapolis – 1999                                                                           Houston – 2003

                             

Salt Lake City – 2005                                                                        Edmonton, Canada – 2008

                           

Guatemala City – 2011                                                                     Poznań, Poland – 2013

                           

Bogotá, Colombia – 2020

Though our roots are in Indianapolis, our goal is to expand to help as many customers as possible. As our services grew nationally, we saw potential in building new foundations for customers in need of fluid analysis internationally. From Edmonton to Bogotá, we continued to lend our services worldwide in hopes of advancing the number of locations our customers can utilize for their analysis.

The POLARIS Laboratories’ Mission

One of the major elements POLARIS Laboratories® represents is the sense of dedication, innovation and discovery. This 25-year long journey that so many people have been part of has been astounding. From a single location in Indianapolis to now operating in multiple regions, the POLARIS Laboratories® name has been a beacon for discovery for many throughout the years. From those who operate under the POLARIS star to those who have journeyed under the star with us, we all come to acknowledge the dedication put into making us shine. Celebrating 25 years of discovery.

Published May 1, 2024